Overrunning decoupler

ABSTRACT

A decoupler having an input member, an output member and a combination one-way clutch and torsional isolator that couples the input and output members. The combination one-way clutch and torsional isolator includes a single helical coil spring. The decoupler being designed to provide torsional damping through a range of torque transmitted through the decoupler, the range including a maximum rated torque for the decoupler.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a 371 U.S. National Stage of InternationalApplication No. PCT/CA2011/000713, filed on Jun. 17, 2011, which claimspriority to U.S. Provisional Application No. 61/358,582, filed on Jun.25, 2010 and U.S. Provisional Application No. 61/406,699, filed on Oct.26, 2010. The contents of the above applications are incorporated hereinby reference in their entirety.

The present disclosure generally relates to drive systems in whichrotary power is transmitted between a source of rotary power and one ormore driven components and an over-running decoupler is employed todampen fluctuations in the torsional load transmitted from the source ofrotary power to the driven component, as well as to permit one or moreof the driven components to be decoupled from and re-coupled to thesource of rotary power to reduce or eliminate torsional loads occurringas a result of acceleration or deceleration of the source of rotarypower relative to the driven component. More particularly, the presentdisclosure relate to a method for inhibiting a resonant condition in anover-running decoupler.

It is known to provide an over-running decoupler in a drive system topermit one or more driven components in the drive system to decouple toreduce or eliminate torsional loads occurring as a result of theacceleration or deceleration of a source of rotary power relative to thedriven component. Exemplary over-running decouplers are disclosed inU.S. patent application Ser. Nos. 10/519,591, 10/542,625, 10/572,128 and10/581,097 and employ a torsionally resilient coupling between adecoupler input member and a decoupler output member. While such devicesare suited for their intended purpose, there remains a need in the artfor an improved decoupler.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features.

In one form, the present teachings provide a decoupler that includes afirst drive member, a second drive member and a one-way clutch andtorsional damper. The first drive member is configured to be coupled toa shaft and includes a first drive surface that extendscircumferentially about and axially along a rotational axis of thedecoupler. The second drive member has a power transmitting portion anda second drive surface. The power transmitting portion is configured toreceive a rotary input to the decoupler or to transmit a rotary outputfrom the decoupler. The second drive surface is coupled to the powertransmitting portion for common rotation about the rotational axis ofthe decoupler. The second drive surface extends circumferentially aboutand axially along the rotational axis of the decoupler. The one-wayclutch and torsional damper is formed by a single helical coil springthat is disposed coaxially about the rotational axis of the decouplerbetween the first drive member and the second drive member.

In another form, the present teachings provide a decoupler having aninput member, an output member and a combination one-way clutch andtorsional isolator that couples the input and output members. Thecombination one-way clutch and torsional isolator includes a singlehelical coil spring.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.Similar or identical elements are given consistent identifying numeralsthroughout the various figures.

FIG. 1 is a schematic illustration of an exemplary engine and frontaccessory drive system that incorporates a decoupler constructed inaccordance with the teachings of the present disclosure, the decouplerbeing disposed between an endless power transmitting element and aninput of a driven device;

FIG. 2 is a schematic illustration of an exemplary engine and frontaccessory drive that incorporates a decoupler constructed in accordancewith the teachings of the present disclosure, the decoupler beingdisposed between an output of the engine and an endless powertransmitting element;

FIG. 3 is a longitudinal cross-section view of the decoupler that isschematically depicted in FIG. 1;

FIG. 4 is an exploded perspective longitudinal cross-section view of thedecoupler that is schematically depicted in FIG. 1;

FIG. 5 is a view similar to that of FIG. 3 but depicting the decoupleras employing first and second drive surfaces that are tapered; and

FIG. 6 is a plot illustrating the torsional loading of a one-way clutch,a one-way clutch with soft engagement and a decoupler as a function ofthe angle of rotation of a drive structure relative to a first drivemember.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION OF THE VARIOUS EMBODIMENTS

With reference to FIG. 1 of the drawings, an over-running decouplerconstructed in accordance with the teachings of the present disclosureis generally indicated by reference numeral 10. The particularover-running decoupler 10 illustrated is particularly suited for usewith a driven device 12, such as an alternator or a supercharger, in adrive system 14 that employs an endless power transmitting element 16,such as a belt or a chain, from a source of rotary power 18, such as anengine or a transmission. Those of skill in the art will appreciate thatthe over-running decoupler 10 could be configured for use in anothertype of drive system (e.g., a drive system employing gears) and/or thatthe over-running decoupler 10 could be employed to transmit rotary powerfrom a drive shaft 20 into the drive system as shown in FIG. 2.Accordingly, it will be appreciated that the teachings of the presentdisclosure have application in a crankshaft decoupler, similar to thosewhich are disclosed in U.S. patent application Ser. Nos. 10/572,128 and10/542,625, the disclosures of which are hereby incorporated byreference as if fully set forth in detail herein.

With reference to FIGS. 3 and 4, the decoupler 10 can include a firstdrive member 30, a second drive member 32, a bearing element 34, aone-way clutch and torsional damper 36, a tubular shield 38 and alubricant 40.

The first drive member 30 can be configured to be coupled for rotationwith the shaft 12 a of the driven device 12 (FIG. 1). In the particularexample provided, the first drive member 30 is generally cup-shaped,having an annular end wall 50, a circumferentially extending side wall52, and first and second shoulders 54 and 56. The annular end wall 50can have a shaft aperture 58 formed therethrough for receipt of theshaft 12 a. The annular end wall 50 can be abutted against a shoulder 12b formed on the shaft 12 a and if desired, a spacer washer 60 can bedisposed between the shoulder 12 b and the annular end wall 50. Thecircumferentially extending side wall 52 can be a generally tubularstructure that can extend axially away from the annular end wall 50. Thecircumferentially extending side wall 52 can define a first drivesurface 64 that can extend circumferentially about and axially along arotational axis 68 of the decoupler 10. In the particular exampleprovided, the first drive surface 64 is defined by a constant radiusover its entire length (i.e., the first drive surface 64 is shaped asthe outer cylindrical surface of a right cylinder) but it will beappreciated that the first drive surface 64 could be configureddifferently (e.g., tapered over all or a portion of its length toconverge toward the rotational axis 68 with decreasing distance from theannular end wall 50 as shown in FIG. 5). The first and second shoulders54 and 56 can be axially spaced apart from one another in any convenientlocation. In the particular example provided, the first shoulder 54 isdefined by a recess formed in the circumferentially extending side wall52 and the annular end wall 50, while the second shoulder 56 is definedby the distal end of the circumferentially extending side wall 52. Itwill be appreciated, however, that a single shoulder may be employed inlieu of the two shoulders depicted in the particular example provided,and/or that one or more specially formed recesses need not be employed.

The second drive member 32 can include a drive structure 70 and aretainer 72 that will be discussed in more detail below. The drivestructure 70 can include a power transmitting portion 74 and cup-shapedstructure 76 that can define a second drive surface 84 and an annularend member 86. The power transmitting portion 74 can be configured toreceive a rotary input to the decoupler 10 or to transmit a rotaryoutput from the decoupler 10, depending on how the decoupler 10 is beingused. In the particular example provided, the power transmitting portion74 is configured to engage the endless power transmitting element 16(FIG. 1) to input rotary power from the endless power transmittingelement 16 (FIG. 1) to the decoupler 10. The power transmitting portion74 can axially overlap all or a portion of the first drive member 30.The cup-shaped structure 76 can be fixedly coupled to the powertransmitting portion 74 such that the second drive surface 84 isdisposed between the power transmitting portion 74 and the annular endmember 86. The second drive surface 84 can be defined by the interiorcircumferential surface of the cup-shaped structure 76 and in theparticular example provided, the second drive surface 84 is defined by aconstant radius over its entire length (i.e., the second drive surface84 is shaped as the outer cylindrical surface of a right cylinder). Itwill be appreciated, however, that the second drive surface 84 could beconfigured differently (e.g., tapered over all or a portion of itslength to converge toward the rotational axis 68 with decreasingdistance from the annular end wall 50 as shown in FIG. 5). The annularend member 86 can extend radially inwardly toward the rotational axis68.

The bearing element 34 can be disposed radially between the first andsecond drive members 30 and 32 to permit relative rotation between thefirst and second drive members 30 and 32. In the particular exampleprovided, the bearing element 34 is a bushing that is fitted to theouter circumferential surface 90 of the first drive member 30 and theinner circumferential surface 92 of the power transmitting portion 74and which has shoulders 94 and 96 that abut the first and secondshoulders 54 and 56, respectively, to maintain the bearing element 34 ina desired axial orientation relative to the first drive member 30. Whilethe bearing element 34 has been illustrated and describe herein as beinga bushing, it will be appreciated that other types of bearing elements,including ball and roller bearings, could be employed in addition to orin lieu of the bushing.

The one-way clutch and torsional damper 36 can comprise a single helicalcoil spring 100 that can have a first end portion 102, a second endportion 104 and an intermediate portion 106 that can be disposed betweenthe first and second end portions 102 and 104. The single helical coilspring 100 can comprise a plurality of coils 108 that can be formed ofan appropriately shaped wire, such as a wire with a generally square orrectangular cross-sectional shape that has a flat or somewhat convexouter surface. The single helical coil spring 100 can be bounded axiallybetween the annular end wall 50 and the annular end member 86.

The coils 108 of the first end portion 102 can be drivingly engaged tothe first drive surface 64 and the coils 108 of the second end portion104 can be drivingly engaged to the second drive surface 84. In theparticular example provided, the coils 108 of the first and second endportions 102 and 104 are engaged in an interference fit to the first andsecond drive surfaces 64 and 84, respectfully. The coils 108 of theintermediate portion 106 can be normally disengaged from the first andsecond drive surfaces 64 and 84 (i.e., when no load is transmittedthrough the decoupler 10) and can be configured to expand and contractin response to changes in a magnitude of the torque that is transmittedthrough the decoupler 10. In this regard, at least a portion of thecoils 108 of the intermediate portion 106 are configured to remain outof contact with the first drive surface 64 and the second drive surface84 when the magnitude of the torque that is transmitted through thedecoupler 10 is less than a predetermined maximum value.

The retainer 72 can be configured to retain the second drive member 32to the first drive member 30 and to limit movement of the second drivemember 32 away from the first drive member 30. The retainer 72 can be adiscrete, washer-like component that can be fitted about the annular endwall 50, abutted against an associated one of the shoulders 94 on thebearing element 34, and fixedly coupled to the power transmittingportion 74. In the particular example provided, the power transmittingportion 74 includes a groove 110 into which the retainer 72 is receivedand a lip 112 formed on the power transmitting portion 74 can be swagedover the retainer 72 to inhibit movement of the retainer 72 in adirection axially outwardly from the groove 110. A transition zone 114between the power transmitting portion 74 and the cup-shaped structure76 can present an annular surface 116 that can abut an opposite one ofthe shoulders 96 on the bearing element 34, but it will be appreciatedthat an internal rib or snap ring could be employed in the alternativeto limit movement of the second drive member 32 toward the first drivemember 30.

The tubular shield 38 can be received into the first and second drivemembers 30 and 32 and the single helical coil spring 100. The tubularshield 38 can be formed of a suitable material, such as a metal orplastic, and can be supported by the shaft 12 a, the first drive member30, and/or the second drive member 70 as desired. In the particularexample provided, the tubular shield 38 comprises a coupling neck 130,which is configured to engage the annular end member 86 in a snap-fitmanner, and a tubular body 132 that can extend from the coupling neck130 into the cavity in which the single helical coil spring 100 ishoused. An end of the tubular body 132 opposite the coupling neck 130can engage (e.g., in a slip-fit or press-fit manner) a shaft retentionnut 140 that can be threadably engaged to the shaft 12 a to fixedlycouple the first drive member 30 to the (FIG. 1). It will be appreciatedthat the coupling neck 130 could be coupled to the annular end member 86in other ways, including a press-fit connection or threads.

The lubricant 40 can be any type of lubricating material, such asappropriate grease, paste or “dry” lubricant material. It will beappreciated that other types of lubricants could be employed, such as anoil (e.g., conventional oil, synthetic oil, traction fluid) and thatseals may be necessary or desirable in such situations. Additionally oralternatively, the wire that forms the single helical coil spring 100could be coated with a wear resistant and/or lubricating material.

The single helical coil spring 100 can be wound so as to uncoil orexpand radially when rotary power is input to the decoupler 10. In theparticular example provided, frictional contact between the second endportion 104 of the single helical coil spring 100 and the second drivesurface 84 applies a torque to the single helical coil spring 100 thatcauses the single helical coil spring 100 to uncoil, which can drivinglyengage the first and second end portions 102 and 104 of the singlehelical coil spring 100 to the first and second drive surfaces 64 and84, respectively. As noted above, the amount by which the intermediateportion 106 of the single helical coil spring 100 uncoils is dependentupon the magnitude of the torque that is transmitted through thedecoupler 10 but at least a portion of the coils 108 of the intermediateportion 106 remain disengaged from the first drive surface 64, thesecond drive surface 84 or both the first and second drive surfaces 64and 84 when a predetermined maximum torque is transmitted through thedecoupler 10 so as to permit the single helical coil spring 100 todampen torsional vibration that would otherwise be transmitted throughthe decoupler 10. Stated another way, the intermediate portion 106 ofthe single helical coil spring 100 provides torsional damping through arange of torque that is transmitted through the decoupler 10 and thisrange of torque includes a maximum rated torque capacity of thedecoupler. It will be appreciated that the torque carrying capacity ofthe decoupler 10 increases as the amount of torque that is transmittedthrough the decoupler 10 increases due to the uncoiling of theintermediate portion 106 of the helical coil spring 100 which permitscoils 108 to contact the first and second drive surfaces 64 and 84. Theuncoiling of the intermediate portion 106 of the helical coil spring 100is also associated with an increase in the spring rate of the helicalcoil spring 100.

The single helical coil spring 100 is also configured to operate withthe first and second drive surfaces 64 and 84 as a one-way clutch thatpermits the first drive member 30 to overrun the second drive member 32.In the particular example provided, frictional contact between the firstend portion 102 of the single helical coil spring 100 and the firstdrive surface 64 when the rotary acceleration of the first drive member30 is greater than that of the second drive member 32 applies a torqueto the single helical coil spring 100 that causes the single helicalcoil spring 100 to coil more tightly. If the coiling of the singlehelical coil spring 100 is sufficiently large, the first end portion 102of the single helical coil spring 100 can disengage the first drivesurface 64 to an extent that permits rotation of the first drive member30 relative to the first end portion 102 of the single helical coilspring 100 to thereby permit the first drive member 30 to overrun thesecond drive member 32.

It will be appreciated that since at least a portion of the intermediateportion 106 of the single helical coil spring 100 does not engage eitherthe first drive surface 64 or the second drive surface 84 duringoperation of the decoupler 10, the single helical coil spring 100 mustbe designed in whole or in part (i.e., a part that includes theintermediate portion 106) to not only carry a load that equals orexceeds a predetermined peak drive torque (i.e., the rated maximumtorque capacity), but also to tune the natural frequency of the systemthat includes the driven device 12 (FIG. 1) in a manner that is belowthe firing frequency of an internal combustion engine used as the sourceof rotary power 18 (FIG. 1).

For example, a typical four cylinder, four-stroke internal combustionengine operating at an idle speed of 750 rpm will have a firingfrequency of 25 Hz. By placing an appropriately configured springelement between the input of the decoupler 10 and the input of thedriven device 12 (FIG. 1), the natural frequency of the system thatincludes the driven device 12 (FIG. 1) can be set to a point that islower than the engine's firing frequency to thereby prevent resonance inthe system (that might otherwise occur as a result of the idling of theengine. One method for setting the natural frequency of the system at apoint below the engine's firing frequency involves the use of a safetyfactor. The safety factor could be a number between 0 and 1, for example0.88 to 0.48, that could be multiplied by the engine firing frequency toprovide a target natural frequency (f_(n)) for the system. It will beappreciated, however, that other techniques may be employed to create amargin of safety, such as subtracting a value, for example apredetermined constant, from the engine firing frequency to obtain thetarget natural frequency (f_(n)) for the system.

The target natural frequency (f_(n)) of the system can be employed todetermine the spring rate (k) of the relevant portion of the singlehelical coil spring 100. One method for determining a spring rateemploys the following formula:k=(2πf _(n))² J

-   -   where:    -   k=the torsional spring rate (Nm/rad) of the relevant portion of        the single helical coil spring 100;    -   f_(n)=the target natural frequency (Hz); and    -   J=the inertia (kgm²) of the driven device 12 (FIG. 1).        It will be apparent to those of skill in the art that the        torsional spring rate of the relevant portion of the single        helical coil spring 100 may be employed for the entirety of the        single helical coil spring 100 and that the length of the        intermediate portion 106 may be sized to appropriately to ensure        that the intermediate portion 106 will remain torsionally        resilient between the first drive member 30 and the second drive        member 32.

With reference to FIG. 6, several plots are depicted to contrast theoperation of the decoupler 10 (FIG. 1) with the operation of two typesof pulleys having only a one-way clutch (these other pulleys wouldreplace the decoupler 10 as it is shown in FIG. 1). The plots depict thedecoupler 10 (FIG. 1) and the two other pulleys when a predeterminedload is applied to the driven device 12 (FIG. 1). More specifically, theplots illustrate the torsional loading of a one-way clutch, a one-wayclutch with soft engagement and a decoupler as a function of the angleof rotation of the drive structure 70 (FIG. 3) relative to the firstdrive member 30 (FIG. 3).

With additional reference to FIGS. 1 and 3, the plot 500 depictssignificant rotation of the first drive member 30 relative to the seconddrive member 32 during the operation of the decoupler 10 when the torquetransmitted through the decoupler 10 is sufficient to drive thepredetermined load on the driven device 12. In contrast, the plot 502depicts a device constructed similar to the decoupler 10 but whichemploys a single helical coil spring that does not include anintermediate portion and is not tuned to the inertia of the drivendevice 12. In this situation, the single helical coil spring willtypically lock in response to a very small angular displacement (e.g.,0.2 degrees) between the clutch input and output members. The plot 504depicts another device that constructed similar to the device of theprevious example, except that the single helical coil spring that doesinclude an intermediate portion but is not tuned to the inertia of thedriven device 12. In this situation, the single helical coil spring willtypically lock in response to a small angular displacement between theclutch input and output members.

It will be appreciated that the above description is merely exemplary innature and is not intended to limit the present disclosure, itsapplication or uses. While specific examples have been described in thespecification and illustrated in the drawings, it will be understood bythose of ordinary skill in the art that various changes may be made andequivalents may be substituted for elements thereof without departingfrom the scope of the present disclosure as defined in the claims.Furthermore, the mixing and matching of features, elements and/orfunctions between various examples is expressly contemplated herein sothat one of ordinary skill in the art would appreciate from thisdisclosure that features, elements and/or functions of one example maybe incorporated into another example as appropriate, unless describedotherwise, above. Moreover, many modifications may be made to adapt aparticular situation or material to the teachings of the presentdisclosure without departing from the essential scope thereof.Therefore, it is intended that the present disclosure not be limited tothe particular examples illustrated by the drawings and described in thespecification as the best mode presently contemplated for carrying outthe teachings of the present disclosure, but that the scope of thepresent disclosure will include any embodiments falling within theforegoing description and the appended claims.

LISTING OF ELEMENTS

decoupler 10 driven device 12 shaft 12a shoulder 12b drive system 14power transmitting element 16 rotary power 18 drive shaft 20 first drivemember 30 second drive member 32 bearing element 34 one-way clutch andtorsional damper 36 tubular shield 38 lubricant 40 annular end wall 50radially extending side wall 52 first shoulder 54 second shoulder 56shaft aperture 58 spacer washer 60 first drive surface 64 rotationalaxis 68 drive structure 70 retainer 72 power transmitting portion 74cup-shaped structure 76 second drive surface 84 annular end member 86outer circumferential surface 90 inner circumferential surface 92shoulder 94 shoulder 96 helical coil spring 100 first end portion 102second end portion 104 intermediate portion 106 coils 108 groove 110 lip112 transition zone 114 annular surface 116 coupling neck 130 tubularbody 132 shaft retention nut 140 plot 500 plot 502 plot 504 idle speed750

What is claimed is:
 1. A decoupler comprising: a first drive member thatis adapted to be coupled to a shaft, the first drive member comprising afirst drive surface that extends circumferentially about and axiallyalong a rotational axis of the decoupler; a second drive member having apower transmitting portion and a second drive surface, the powertransmitting portion being configured to receive a rotary input to thedecoupler or to transmit a rotary output from the decoupler, the seconddrive surface being coupled to the power transmitting portion for commonrotation about the rotational axis of the decoupler, the second drivesurface extending circumferentially about and axially along therotational axis of the decoupler; and a one-way clutch and torsionaldamper formed by a single helical coil spring disposed coaxially aboutthe rotational axis of the decoupler between the first drive member andthe second drive member, wherein the single helical coil spring isconfigured to provide torsional damping through a range of torquetransmitted through the decoupler, the range of torque including a ratedmaximum torque capacity of the decoupler.
 2. The decoupler of claim 1,wherein the single helical coil spring comprises a first end portion,which is abutted against the first drive surface, a second end portion,which is abutted against the second drive surface, and an intermediateportion between the first and second end portions, the intermediateportion comprising a plurality of coils that are configured to expandand contract in response to changes in a magnitude of a torque that istransmitted through the decoupler, at least a portion of the coils beingconfigured to not contact the first and second drive surfaces when themagnitude of the torque is less than a predetermined maximum torque. 3.The decoupler of claim 1, wherein the first and second drive memberscomprise radially extending wall members that are disposed on oppositeaxial ends of the single helical coil spring.
 4. The decoupler of claim1, wherein the power transmitting portion is configured to engage anendless power transmitting element.
 5. The decoupler of claim 1, whereinthe first drive member is generally cup-shaped.
 6. The decoupler ofclaim 1, wherein at least a portion of the first drive surface istapered.
 7. The decoupler of claim 1, wherein at least a portion of thesecond drive surface is tapered.
 8. The decoupler of claim 7, wherein atleast a portion of the first drive surface is tapered.
 9. The decouplerof claim 1, wherein the power transmitting portion axially overlaps atleast a portion of the first drive surface.
 10. The decoupler of claim9, wherein a bearing element is disposed radially between the powertransmitting portion and the first drive member.
 11. The decoupler ofclaim 10, wherein the bearing element is a bushing.
 12. The decoupler ofclaim 11, wherein the first drive member has a pair of axially spacedapart shoulders that cooperate with shoulders formed on the bushing toinhibit axial movement of the bushing relative to the first drivemember.
 13. The decoupler of claim 12, wherein the second drive membercomprises an abutting wall that abuts one of the shoulders of thebushing on a side opposite a corresponding one of the first drivemember.
 14. The decoupler of claim 13, wherein the second drive memberfurther comprises a retainer coupled to the power transmitting portion,the retainer abutting the other one of the shoulders of the bushing on aside opposite an associated one of the shoulders on the first drivemember.
 15. The decoupler of claim 1, wherein a tubular shield isdisposed radially inwardly of the single helical coil spring.
 16. Thedecoupler of claim 15, further comprising a shaft retention nut that isadapted to be threadably engaged to the shaft, the shaft retention nutbeing received in the tubular shield and engaging a radially innersurface of the tubular shield.
 17. The decoupler of claim 15, whereinthe tubular shield is snap-fit to the second drive member.
 18. Thedecoupler of claim 15, further comprising a lubricant disposed betweenthe single helical coil spring and at least one of the first and seconddrive surfaces.
 19. A decoupler having an input member, an output memberand a combination one-way clutch and torsional isolator that couples theinput and output members, the combination one-way clutch and torsionalisolator comprising a single helical coil spring, wherein the torsionalisolator is effective through a range of torque transmitted through thedecoupler, the range of torque including a rated maximum torque capacityof the decoupler.
 20. The decoupler of claim 19, wherein the torsionalspring rate and torque capacity of decoupler increase as the amount oftorque transmitted through the decoupler increases toward apredetermined maximum torque.
 21. The decoupler of claim 20, wherein thesingle helical coil spring is physically constrained at thepredetermined maximum torque to limit a peak stress in a wire that formsthe single helical coil spring.